first prototype (patent not yet applied for)

[sloan]

Time to sort out the design requirements document...

What I'm aiming for is a lightweight package suitable for handing off to FedEx, UPS, LuggageForward (check them out!) for a "date specific" delivery. Checked baggage is on the list - but far down the list.

Checked baggage introduces the requirement for someone else (i.e., TSA) to open, inspect, and repack.
For these purposes, a zippered bag looks like a good idea. But, I think I'll put that idea on hold for the time being.

The current design has a minor problem that can be addressed by cross-bracing. I think the cardboard shipping carton will be sufficient - my next line of defense will be diagonal tension elements

Penetration resistance might be increased with plastic panels - in my opinion, this is easy and cheap to do using a cardboard shipping carton. It is much easier once you construct a bag - but I don't think the expense of the bag is justified

In my experience, the OUTSIDE of baggage is the first thing to go. I like the idea of using semi-disposable, very cheap cardboard for the outside. When (not if) it is damaged, just swap it out.
It's a question of spending $8 every three trips or $100 every 25 trips.

So, the bag is a plus if going through TSA and might be a plus to help with cross-bracing. But, I don't really want to go through TSA and the need for cross-bracing is not severe (I suspect it is, in fact, non-existant).

So...I'm turning my attention back to the details of the original design.

Big questions at the moment:

a) I'd really like something like a 3" diameter ring held firmly in place as close as possible to each corner. The ideal solution would be a factory item "3-way elbow + lashing ring". Second best is a ring lashed to the 3-way elbow. I do that now with the 9" bungee-ball loops, but these are too elastic and stretch so that the ring would be too far from the corner. So...I'm looking for the best replacement for the 9" bungee-ball loops. The Boy-Scout solution is nylon cord tied into a loop (better - tied and then heat fused?). Next might be a custom length strap with a ring on each end. Best of all might be a pulley belt. Any kind of flexible, strong, inelastic loop of just the right length.

b) I'm interested in cheap modifications to standard cardboard shipping cartons that allow for multiple sealing/unsealing. It's hard to beat strapping tape (until TSA wants to open it) - but perhaps there are some ideas out there. Right now, my thoughts tend towards Velcro(TM) to hold flaps closed - PLUS light duty tape to smooth the edges. My primary concern is having something snag on a flap corner and rip the cardboard. (yes, Rick - the bag would do this; I'm simply unwilling to pay that much).

Finally - I'm so pleased with the way that the two different kinds of cargo nets I have fit into this project that I've decided to order more to complete the package. I'll stretch the lightweight 15"x30" nets on the 2'x3' sides of the box and the heavyweight (seat-belt webbing) 24"x30" webbing on the 3'x3' sides. I have half the required number now (2 lightweight, 1 heavyweight) and am about to order the rest. I can't quite articulate all the ways in which these might prove useful - but they simply LOOK perfect on the frame, so I can't resist.

one more...suppose I did want to purchase a 3'x3x'2' box (rigid, good penetration resistance, easy open/easy close). Just the shell - no goodies like interior padding, casters, handles, etc. Where should I look? How much should I expect it to WEIGH? Full ATA compliance is not necessary.

Oh...wait....Rick says he can build a bag in a weekend. Rick - how much would you charge for that? In blue.